Apparatus for Packing Leafy Produce into a Tray

ABSTRACT

An automated machine for packing leafy produce into a tray involving a plunger, the plunger having an actuator arm and a footpad, the footpad having an upper surface and a lower surface, being in moveable relation to the actuator arm, for contacting the leafy produce.

PRIORITY CLAIM

This application is a continuation in part of application Ser. No.11/232,830, entitled “Automated Plunger assembly, Machine and Method”filed on Sep. 21, 2005 (retitled “Apparatus for Packing Leafy Productinto a Tray” by examiner's amendment), and claims priority thereto. Theparent application and all amendments thereto are hereby expresslyincorporated by reference. Claims 1 through 8 herein were previouslyallowed in the parent application. Claims 9 through 16 are new.

TECHNICAL FIELD

The present invention relates to mechanized processing and packaging ofagricultural products and produce.

BACKGROUND ART

The currently existing art involves several machines for packing leafyproduce, such as “spring mix,” spinach, lettuce, endive, arugula, andthe like. One such instance of existing art is a packing machine thatfills a container with leafy produce then fits a lid onto such containerhaving the produce, but damages the leafy produce at the rim of thecontainer, thereby shortening the shelf life of the product. Thisproblem in the related art occurs, because the leafy produce has atendency to spring back upon loading into the container, to overhang therim of the container, and to be subsequently damaged during fitting ofthe lid. To counteract this adverse result, agricultural processors haveused manual labor for “post-packing”the leafy produce, e.g., using aproduction line of approximately six gloved workers who manuallyreposition the leafy produce in the container prior to thereon fittingthe lid. Thus, a long-felt need is seen to exist for an automatedapparatus for efficiently packing leafy produce, eliminating damagethereto, and minimizing processing time.

DISCLOSURE OF THE INVENTION

The present inventive concept pertains to the mechanized packing of aproduct, such as leafy produce, into a tray without damage andminimizing processing time. In a preferred embodiment, an automatedmachine for packing leafy produce into a tray generally comprises: oneor more transfer chutes for receiving the portions and guiding eachtray-sized individual portions into one of the trays; flop gates withinthe chutes to control the flow of produce through the various chutes; aconveyor for moving the trays into a position below the transfer chute'sdischarge opening to receive the tray-sized portions; a plunger assemblywith at least one linear plunger having a first footpad for moving theportions through the transfer chute discharge opening into the tray, aram, cylinder and piston rod, a retracted first position with thefootpad outside of the transfer chute and an extended second positionwith the footpad inside the transfer chute proximal to the dischargeopening. Mechanized moving parts, including the flop gates and plungerassembly, are coupled with automated actuators to allow automation andsequencing of movement.

Advantages of the present inventive concept include the promotion ofincreased production levels, minimization of rejected product, andminimization of the number of workers required in the production line.Other features of the present inventive concept and its embodiments aredisclosed, or are apparent, in the section entitled “DetailedDescription of the Invention,” disclosed, infra.

BRIEF DESCRIPTION OF THE DRAWING

For a better understanding of the present invention, reference is madeto the below-referenced accompanying Drawing. Reference numbers refer tothe same or equivalent parts of the present invention throughout theseveral figures of the Drawing.

FIG. 1 is an upward perspective view of an automated packing machine, inaccordance with the present invention, with a plunger assemblycomprising two plungers per transfer chute.

FIG. 2 is a downward perspective view of the automated packing machine,as shown in FIG. 1, in accordance with the present invention, with aplunger assembly comprising two plungers per transfer chute.

FIG. 3 is an upward perspective view of an automated packing machine,shown without the support frame for clarity only, in accordance with thepresent invention, with a plunger assembly comprising two plungers pertransfer chute.

FIG. 4 is a downward perspective view of a plunger assembly comprisingtwo plungers per transfer chute with a mounting bracket, and without thesupport frame for clarity only, in accordance with the presentinvention.

FIG. 5 is a downward perspective view of a plunger assembly comprisingtwo plungers per transfer chute an automated plunger assembly, shownwithout a mounting bracket and without the support frame for clarityonly, in accordance with the present invention.

FIG. 6 is side view of a plunger assembly comprising two plungers pertransfer chute, wherein at least one plunger is disposed outside atransfer chute and a funnel, shown without a mounting bracket andwithout the support frame for clarity only, in accordance with a firstembodiment of the present invention.

FIG. 7 is side view of a plunger assembly comprising two plungers pertransfer chute, wherein at least one plunger is disposed inside aproduct transfer chute and a funnel, shown without a mounting bracketand without the support frame for clarity only, in accordance with asecond embodiment of the present invention.

FIG. 8 is a front view of an automated packing machine, being seriallydisposed in an assembly line, in accordance with an embodiment of thepresent invention.

FIG. 9 is an upward perspective view of an automated packing machine, inaccordance with the present invention, with a plunger assemblycomprising one plunger per transfer chute.

FIG. 10 is a downward perspective view of the automated packing machine,as shown in FIG. 9, in accordance with the present invention, with aplunger assembly comprising one plunger per transfer chute.

FIG. 11 is an upward perspective view of an automated packing machine,shown without the support frame for clarity only, in accordance with thepresent invention, with a plunger assembly comprising one plunger pertransfer chute.

FIG. 12 is a downward perspective view of a plunger assembly comprisingone plunger per transfer chute with a mounting bracket, and without thesupport frame for clarity only, in accordance with the presentinvention.

FIG. 13 is a downward perspective view of a plunger assembly comprisingone plunger per transfer chute an automated plunger assembly, shownwithout a mounting bracket and without the support frame for clarityonly, in accordance with the present invention.

FIG. 14 is side view of a plunger assembly comprising one plunger pertransfer chute, wherein the plunger is disposed outside a transfer chuteand a funnel, shown without a mounting bracket and without the supportframe for clarity only, in accordance with an embodiment of the presentinvention.

FIG. 15 is side view of a plunger assembly comprising one plunger pertransfer chute, wherein the plunger is disposed inside a producttransfer chute and a funnel, shown without a mounting bracket andwithout the support frame for clarity only, in accordance with anembodiment of the present invention.

MODES FOR CARRYING OUT THE INVENTION

FIG. 1 illustrates, in a perspective view, an automated packing machine1000, comprising a plunger assembly, in accordance with the presentinvention. The plunger assembly 100 for packing leafy produce 10 into atray 20, comprises at least one plunger 30, each at least one plunger 30having at least one actuator arm 40 and at least one footpad 50, the atleast one footpad 50 having an upper surface 50 a and a lower surface 50b, being in moveable relation to the at least one respective actuatorarm 40, for contacting the leafy produce 10. The moveable relationcomprises a structure 40 a (not shown) for articulating the at least onefootpad 50 about each respective at least one actuator arm 40. Thearticulating structure 40 a is disposed at a location selected from agroup consisting essentially of a periphery of the footpad 50 at theupper surface 50 a, a centerline of the footpad 50 at the upper surface50 a, and a location between a centerline of the footpad 50 and aperiphery of the footpad 50. The machine 1000 is shown in FIG. 1 with aset of plungers 30, e.g., primary plungers, with a support frame 1001,with a hopper 80, comprising a primary chute 1002 and a secondary chute(pant-leg chute) 1003 for facilitating filling of two trays at a givenfilling interval, and a feeder 90, comprising a feature such as aproduct transfer (funnel) 120, for clarity and by example only. Theprimary chute 1002 comprises a flop gate 1002 a and a flop gate actuator1002 b, as shown in FIG. 12 which is described, infra, and a flop gatecontrol device 1002 c, such as a solenoid switch, for controlling theflop gate actuator 1002 b.

By example only, the articulating structure 40 a comprises a featureselected from a group consisting essentially of a hinge, a pin, and aball and socket combination. The at least one footpad 50 comprises acorrugated surface 50 c at the lower surface 50 b for minimizing surfacetension of the leafy produce 30 which facilitates release of the leafyproduce 10 from the footpad 50 when the plunger 30 retracts, Thecorrugated surface 50 c comprises a configuration such as a sinusoidalprofile and a square wave profile, the sinusoidal profile beingpreferred. The at least one actuator arm 40 comprises a structure foradjusting stroke (not shown), wherein the stroke is effected byprogrammable logic control (PLC), such as a magnetic read switchdisposed on the actuator arm 40 and a PLC-defined dwell time. Theactuator arm 40 comprises an actuator arm housing 40 b such as a hollowtube. The at least one footpad 50 comprises a structure for adjustingsize (not shown), especially the platform size. The footpad sizeadjusting structure comprises a feature such as at least one retractablefootpad portion and a set of interchangeable footpads 50 which areinterchangeable by loosening a fitting 41 a at a proximal end of aguide-rod 41 and a fitting 50 d at the upper surface 50 a of the footpad50, wherein each footpad 50 of the set comprises a distinct size.

Plunger 30 is angularly disposed in relation to the tray 10. The plunger30 is activated, i.e., deployed by a feedback and control unitcomprising sensor 110 (discussed, infra), upon sensing the presence of atray 20 and retracted upon packing the tray 20 with the leafy produce10. The apparatus 100 comprises a primary plunging mechanism 31, asshown and described, infra, with respect to FIG. 12. The footpad 50 ispreferably selected to fit the size of the opening of the tray 20. Inparticular, as the footpad 50 reaches the bottom of the stroke, a puffof gas, such as air and nitrogen (N₂), as well as an inert gas, such ashelium (He) and argon (Ar), is administered through a manifold disposedat the periphery of the upper surface 50 a of the footpad 50. After thedwell period has lapsed, the plunger 30 retracts; and the filled tray 20is stepped forward by the conveyer 60 for applying the lid 130.

FIG. 2 illustrates, in a downward perspective view, the automatedpacking machine 1000, as shown in FIG. 1, comprising the automatedplunger assembly 100, in accordance with the present invention.

FIG. 3 illustrates, in an upward perspective view, an automated packingmachine 1000, comprising an automated plunger assembly 100, shownwithout the support frame 1001 for clarity only, in accordance with thepresent invention.

FIG. 4 illustrates, in a downward perspective view, an automated plungerassembly 100, shown in relation to a feeder 90, such as a producttransfer chute 120 and a funnel, with a mounting bracket 32, and withoutthe support frame 1001 for clarity only, in accordance with the presentinvention. A set of plungers 30 are lowered into the product transferchute 120 by the primary plunging mechanism 31.

FIG. 5 illustrates, in a downward perspective view, an automated plungerassembly 100, shown without a mounting bracket 32 and without thesupport frame 1001 for clarity only, in accordance with the presentinvention.

FIG. 6 illustrates, in a side view, an automated plunger assembly 100,wherein at least one plunger 30 is disposed outside a feeder 90, such asa product transfer chute 120 and a funnel, shown without a mountingbracket 32 and without the support frame 1001 for clarity only, inaccordance with a first embodiment of the present invention.

FIG. 7 illustrates, in a side view, an automated plunger assembly 100,wherein at least one plunger 30 is disposed a feeder 90, such as aproduct transfer chute 120 and a funnel, shown without a mountingbracket 32 and without the support frame 1001 for clarity only, inaccordance with a second embodiment of the present invention.

FIG. 8 illustrates, in a front view, an automated packing machine 1000,comprising automated plunger assemblies 100, 100′, being seriallydisposed in an assembly line, wherein the second apparatus 100′ acts asa secondary set of plungers, in accordance with a fifth embodiment ofthe present invention. The primary chute 1002 comprises a flop gate 1002a, a flop gate actuator 1002 b, and a flop gate control device 1002 c,such as a solenoid switch, for controlling the flop gate actuator 1002b. The flop gate 1002 a limits the amount of leafy produce 10 which ispacked at a given packing interval.

Referring to both FIGS. 1 and 8, the automated machine 1000 for packingleafy produce 10 into a tray 20, comprises a conveyor 60 having astepper 70 for accommodating and moving at least one tray 20, a trayfiller generally comprising a hopper 80 for channeling the leafy produce10 and a feeder 90 for receiving the channeled leafy produce 10 and forfilling the leafy produce 10 into the at least one tray 20, and anautomated plunger assembly 100 for packing the leafy produce 10 into atray 20, the apparatus 100 comprising at least one plunger 30, each atleast one plunger 30 having at least one actuator arm 40 and at leastfootpad 50, the at least one footpad 50 having an upper surface 50 a anda lower surface 50 b, being in moveable relation to the at least onerespective actuator arm 40, for contacting the leafy produce 10.

Machine 1000 further comprises a sensor 110 for detecting the presenceof the at least one tray 20 and for supplying an electronic signal tothe feeder 90 to effect its opening for filling the at least one tray 20with the leafy produce 10 (a designated amount thereof). The feeder 90includes a product transfer chute 120 or a funnel being disposed intothe at least one tray 20 upon receipt of the electronic signal from thesensor 110. In the alternative, the plunger 30 is disposed within theproduct transfer chute 120.

FIGS. 9 though 16 similarly depict a packing machine and its componentswith a preferred configuration, having a plunger assembly comprisingonly one plunger per transfer chute. This embodiment has the advantageof fewer moving parts, with consequent added simplicity in coordinatingand automating the plunger actuation as well as being easier to clean,maintain and sanitize.

Information as herein shown and described in detail is fully capable ofattaining the above-described object of the invention, the presentlypreferred embodiment of the invention, and is, thus, representative ofthe subject matter which is broadly contemplated by the presentinvention. The scope of the present invention fully encompasses otherembodiments which may become obvious to those skilled in the art, and isto be limited, accordingly, by nothing other than the appended claims,wherein reference to an element in the singular is not intended to mean“one and only one” unless explicitly so stated, but rather “one ormore.” All structural and functional equivalents to the elements of theabove-described preferred embodiment and additional embodiments that areknown to those of ordinary skill in the art are hereby expresslyincorporated by reference and are intended to be encompassed by thepresent claims.

Moreover, no requirement exists for a device or method to address eachand every problem sought to be resolved by the present invention, forsuch to be encompassed by the present claims. Furthermore, no element,component, or method step in the present disclosure is intended to bededicated to the public regardless of whether the element, component, ormethod step is explicitly recited in the claims. However, variouschanges and modifications in form, material, and fabrication materialdetail may be made without departing from the spirit and scope of theinventions as set forth in the appended claims should be readilyapparent to those of ordinary skill in the art. No claim herein is to beconstrued under the provisions of 35 U.S.C. 112, sixth paragraph, unlessthe element is expressly recited using the phrase “means for.”

INDUSTRIAL APPLICABILITY

The present invention industrially relates to agricultural apparatuses,machines, and methods. More particularly, the present inventionindustrially relates to agricultural apparatuses, machines, and methodsfor processing produce. Even more particularly, the present inventionindustrially relates to agricultural apparatuses, machines, and methodsfor packing processed produce.

1. An apparatus for packing leafy produce into a tray, comprising: a. Aprimary chute for receiving and apportioning the leafy produce intoindividual portions; b. A transfer chute, having two sidewalls, two endwalls and a discharge opening, for receiving the portions and guidingeach of said tray-sized individual portions through a discharge openinginto one of the trays; c. a means for conveying said trays to a positionbelow said discharge opening of said transfer chute to receive saidtray-sized individual portions. d. A first linear plunger having a firstfootpad for moving the portions through the transfer chute dischargeopening into the tray, said plunger having a retracted first positionwith the footpad outside of the transfer chute and an extended secondposition with the footpad inside the transfer chute proximal thedischarge opening, said first plunger having a first ram, cylinder andpiston rod; and e. A second linear plunger having a second footpad formoving the portions through the transfer chute discharge opening intothe tray, said second plunger being oriented to said first plunger at anacute angle, and having a second ram, cylinder and piston rod, saidfirst and second footpads further each having a manifold for dispersinga puff of gas as the linear plungers reach the extended position.
 2. Theapparatus as in claim 1 wherein at least one of the first and secondfootpads is detachably coupled to the respective first and second linearplungers by a coupling.
 3. The apparatus as in claim 2 wherein thecoupling is at a position selected from the group of positionsconsisting of a periphery of the footpad at an upper surface, acenterline of the footpad at an upper surface, and a location betweenthe centerline and the periphery.
 4. The apparatus as in claim 3 whereinat least one of the first and second footpads has a corrugated surfaceon the side contacting the portion in the tray.
 5. An apparatus as inclaim 1, wherein the primary chute includes a secondary chute, whereinthe primary chute further includes a flop gate for limiting the amountof leafy produce to be filled in two trays, a flop gate actuator, and aflop gate control device for controlling the flop gate actuator, andwherein the secondary chute includes at least two chute branches forfacilitating filling of at least two trays simultaneously.
 6. Anapparatus as in claim 1 further having at least one footpad manifold fordispersing a puff of gas.
 7. An apparatus as in claim 1, wherein saidmeans for conveying said trays comprises a conveyor having a stepper fordisposing and moving the trays below said discharge opening.
 8. Anapparatus, as recited in claim 1, wherein at least one of the footpadstraverses a path substantially along one of the sidewalls of thetransfer chute.
 9. An apparatus for packing leafy produce into trayscomprising: a. A primary chute for receiving and apportioning the leafyproduce into individual tray-sized portions; b. At least two transferchutes, having two sidewalls, two end walls, and a discharge opening,for receiving the portions and guiding each of said tray-sizedindividual portions through said discharge opening into one of thetrays; c. A linear plunger having a first footpad for moving theportions through the transfer chute discharge opening into the tray,said plunger having a retracted first position with the footpad outsideof the transfer chute and an extended second position with the footpadinside the transfer chute proximal to the discharge opening, saidplunger having a ram, cylinder and piston rod.
 10. The apparatus as inclaim 9 wherein at least one of the footpads is detachably coupled tothe respective plunger by a coupling.
 11. The apparatus as in claim 10wherein the coupling is at a position selected from a group on positionsconsisting of a periphery of the footpad at an upper surface, acenterline of the footpad at an upper surface, and a location betweenthe centerline and the periphery.
 12. The apparatus as in claim 11wherein at least one of the footpads has a corrugated surface on theside contacting the portion in the tray.
 13. An apparatus as in claim 9wherein the primary chute includes at least one secondary chute, whereinthe primary chute further includes a flop gate for limiting the amountof leafy produce to be filled in two trays, a flop gate actuator, and aflop gate control device for controlling the flop gate actuator, andwherein the at least one secondary chute includes two chute branches forfilling of at least two trays simultaneously.
 14. An apparatus as inclaim 9 further having at least one footpad manifold for dispersing apuff of gas.
 15. An apparatus as in claim 9 wherein said means forconveying said trays comprises a conveyor having a stepper for disposingand moving said trays below said discharge opening.
 16. An apparatus asin claim 15 wherein at least one of the footpads traverses a pathsubstantially along one of the sidewalls of the product transfer chute.